A heat exchanger and battery unit structure is provided for cooling battery units (or cells) where the thermally conductive nature of the battery forms a cooling path. The heat exchanger is in the form of a cooling element provided with an engaging device formed on or attached to an outer surface of the cooling plate for receiving and/or engaging with a corresponding engaging portion on a battery unit (or cell). The interconnection between the battery unit (or cell) and heat exchanger creates a mechanical interlock between the two components that results in improved heat transfer properties between the two components.
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16. A heat exchanger comprising:
spaced-apart first and second walls sealingly joined together at their periphery and defining an enclosed fluid channel therebetween, the heat exchanger having a fluid inlet in fluid communication with an inlet end of said enclosed fluid channel and a fluid outlet in fluid communication with an outlet end of said enclosed fluid channel, said enclosed fluid channel extending between said inlet end and said outlet end between said first and second walls, wherein one of said first and second walls defines a primary heat transfer surface for heat exchange with said at least one battery unit;
a second engaging device formed on an outer surface of and extending away from the primary heat transfer surface defined by one of said first and second walls that define the enclosed fluid channel of the heat exchanger for coupling to and mechanically engaging with a first engaging device formed on or attached to an outer housing of a battery unit arranged on said primary heat transfer surface;
wherein the mechanical engagement between the first and second engaging devices secures the base portion of said battery unit in heat transfer relationship to said primary heat transfer surface of said heat exchanger; and
wherein the second engaging device is one of a plurality of second engaging devices, the second engaging devices being arranged so that their spatial distribution across the primary heat transfer surface for engagement with corresponding first engaging devices minimizes thermal resistance between the heat exchanger and said at least one battery unit; and wherein the surface area of the primary heat transfer surface underneath the base portion of the at least one battery unit is greater than the surface of the second engaging device in contact with first engaging device of the at least one battery unit.
1. A heat exchanger and battery unit structure, comprising:
at least one battery unit having an outer housing, the outer housing having a base portion;
at least one heat exchanger plate pair comprising first and second spaced-apart walls that are sealingly joined together at their periphery so as to define an enclosed fluid channel between said first and second walls, the heat exchanger plate further comprising a fluid inlet formed therein in fluid communication with an inlet end of said enclosed fluid channel and a fluid outlet formed therein in fluid communication with an outlet end of said enclosed fluid channel for inletting and discharging a liquid fluid to and from said enclosed fluid channel, said enclosed fluid channel extending between said inlet end and said outlet end between said first and second walls, wherein one of said first and second walls defines a primary heat transfer surface for heat exchange with said at least one battery unit;
a first engaging device formed as part of a bottom surface of the base portion of the battery unit;
a second engaging device formed on an outer surface of and extending away from the primary heat transfer surface defined by one of said first and second walls that define the enclosed fluid channel of the heat exchanger plate;
wherein one of the first engaging device and the second engaging device is received within and mechanically engages the other of the first engaging device and the second engaging device such that the mechanical engagement between the first engaging device and the second engaging device secures the base portion of the at least one battery unit to the primary heat transfer surface of said at least one heat exchanger plate; and
wherein the corresponding first and second engaging devices are arranged so that their spatial distribution across the primary heat transfer surface minimizes thermal resistance between the at least one battery unit and the at least one heat exchanger plate; and wherein the surface area of the primary heat transfer surface underneath the base portion of the at least one battery unit is greater than the surface of the second engaging device in contact with first engaging device of the at least one battery unit.
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wherein said base plate has a second surface generally opposed to said first surface, said second surface of said base plate mechanically engaging with said second engaging device.
12. The heat exchanger and battery unit system as claimed in 11, wherein the protruding member is a fin.
13. The heat exchanger and battery unit system as claimed in
14. The heat exchanger and battery unit system as claimed in
15. The heat exchanger and battery unit system as claimed in
17. A heat exchanger as claimed in
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The present application claims priority to U.S. provisional application Ser. No. 61/407,972 filed on Oct. 29, 2010, and incorporated by reference in its entirely herein.
The present disclosure relates generally to the cooling of thermally conductive batteries by mechanical interlock.
Different types of battery cells, such as a round cell, a prismatic cell or a pouch cell are known. In the case of a round cell or a prismatic cell, the active material, containing the electrodes and separators, is generally rolled up into a coil and placed in a robust aluminum housing. In the case of the pouch cell, the individual layers of the active material are stacked or folded, and packaged into a flexible aluminum composite film.
In operation, a current flow, either a charge or discharge, generates heat due to both electrochemical and electrical impedance effects. Due to temperature limitations at both low and high temperatures it is desirable to control an operating temperature range for batteries to ensure optimal performance of the battery.
Various heat exchanger structures and battery unit arrangements have been developed for providing cooling (and/or heating) to thermally conductive batteries. For instance, it is known for heat to be dissipated or transported from (or to) the exterior surfaces of the battery housing by (i) exposing the external surfaces to circulating air or by (ii) pressing a chilled (or heated) surface, whether it be a fluid-carrying heat exchanger cooling plate or a non-fluid carrying metallic conduction plate either between or in contact with battery cell surfaces. When the battery cell surfaces are in contact with a chilled (or heated) surface, there is concern with regard to thermal contact resistance and thermal constriction resistance as well as the mechanical aspects of maintaining sufficient contact/pressure between the two, especially in the application of automotive power batteries. As well, the contacting surfaces themselves must be sufficiently conformal to allow for good thermal contact between the battery unit and the cooling plate. When the battery cell surfaces are cooled by exposing the surfaces to circulating air, the spacing-apart of individual battery units or cells results in increased space allowances. As well, this method has more limited cooling effects and also makes it more difficult to recover heat for uses in other vehicle systems. Accordingly, known methods for cooling batteries tend to have high costs, increased space and/or weight penalties, as well as high tolerance requirements, all of which are desirable to overcome.
In one aspect, the present disclosure relates to a heat exchanger and battery unit structure, having at least one battery unit having an outer housing, the outer housing having a base portion; at least one heat exchanger plate having spaced-apart first and second walls defining a fluid channel therebetween, the heat exchanger plate having a fluid inlet and a fluid outlet in communication with said fluid channel; a first engaging device formed on or attached to the outer housing of the battery unit; a second engaging device formed on or attached to an outer surface of at least one of the first and second walls of the heat exchanger plate; wherein one of the first engaging device and the second engaging device is received within the other of the first engaging device and the second engaging device such that the at least one battery unit and the at least one heat exchanger plate are locked together upon engagement of the first and second engaging devices.
In one embodiment, the disclosure relates to a heat exchanger and battery unit system, wherein the at least one heat exchanger plate comprises a pair of mating first and second plates.
In another embodiment, the disclosure relates to a heat exchanger and battery unit system, furthering containing a turbulizer positioned in the fluid channel of the at least one heat exchanger plate.
In a further embodiment, the disclosure relates to a heat exchanger and battery unit system, furthering including an electrical isolation layer positioned between the first and second engaging devices of the at least one battery unit and at least one heat exchanger plate, the electrical isolation layer being engaged therewith.
In a still further embodiment, the disclosure relates to a heat exchanger and battery unit system, wherein the at least one battery unit is a plurality of battery units and the base portion is in the form of a current collector plate, the plurality of battery units being spot welded to the current collector plate.
In another further embodiment, the disclosure relates to a heat exchanger and battery unit system, further including an electrical isolation layer positioned between the current collector plate and the heat exchanger plate.
In another still further embodiment, the disclosure relates to a heat exchanger and battery unit system, wherein the first engaging device has a base plate coupled to a plurality of spaced-apart protruding members, the plurality of spaced-apart protruding members adapted for releasably-affixing the battery unit.
In a still further embodiment, the disclosure relates to a heat exchanger and battery unit system, wherein the first engaging device has a plurality of spaced-apart protruding members coupled to the second engaging device, the plurality of spaced-apart protruding members adapted for releasably-affixing the battery unit.
In one embodiment, the disclosure relates to a heat exchanger and battery unit system, wherein the protruding member is a fin.
In another embodiment, the disclosure relates to a heat exchanger and battery unit system, wherein the fins are welded, brazed or soldered to the base plate of the first engaging device.
In a further embodiment, the disclosure relates to a heat exchanger and a heat exchanger and battery unit system, wherein the outer housing of the battery is a hard case or is a flexible pouch.
In a still further embodiment, the disclosure relates to a heat exchanger and battery unit system, wherein the protruding member further contains a biasing means for biasing movement of the protruding member.
In still another further embodiment, the disclosure relates to a heat exchanger and a heat exchanger and battery unit system, wherein the biasing means is a generally S-shaped structure.
In another further embodiment, the disclosure relates to a heat exchanger and battery unit system, wherein the battery is in contact with or is spaced from the first wall of the heat exchanger.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the attached Figures, wherein:
Referring now to the drawings,
As shown, each battery unit 11 comprises an outer case or housing 14 that houses the internal components (not shown) of the battery unit 11, as is known in the art. In the subject embodiment, the outer housing 14 is constructed on a welded or an extruded base portion 16 having a first engaging device formed therein. In some embodiments, the base portion 16 may be formed of aluminum or steel and may be impact formed or formed as a welded assembly. In the embodiment shown, the first engaging device is in the form of a plurality of sockets or recessed openings 18 formed in the bottom surface of the base portion 16 of the battery unit 11. The recessed openings 18 are spaced-apart along the length of the outer housing 14 at predetermined intervals based on the particular design and application of the battery unit 10 and heat exchanger structure 12.
In order to provide cooling to the individual battery units 11, a heat exchanger structure 12 in the form of a cooling element or plate 20 is provided. In general, the cooling plate 20 is a flat, tubular member with spaced-apart first and second walls 22, 24 that define a fluid channel 26 therebetween. The cooling plate 20 is in communication with fluid inlet and outlet structures 27, 28 for directing fluid into and out of the fluid channel 26. While the fluid inlet and outlet structures 27, 28 have been shown as being formed on and extending outwardly and away from the outer surface of the cooling plate 20, in some embodiments, the fluid inlet and outlet structures 27, 28 may instead be formed on the perimeter of the cooling plate 20 (for example as shown in
With regard to fluid passage 26, it will be understood that the fluid channel 26 may be in the form of any, generally serpentine flow path through the cooling plate 20 that provides the desired heat exchange profile for cooling (and/or heating) the battery units 11. For instances, fluid channel 26 may be generally U-shaped (for example in instances where the inlet and outlet structures 27, 28 are formed on the same side of the cooling plate 20), or may take on the form of any serpentine or circuitous route through the cooling plate 20 from one end to the other (i.e. in instances where the inlet/outlet structures are formed on opposed sides of the cooling plate 20).
One of the first and second walls 22, 24 of the cooling plate 20 is provided with a second engaging device which cooperates with the first engaging device on each battery unit 11. In the subject embodiment, the second engaging device is in the form of “pegs” or protruding members 30 which are welded or brazed or soldered, for example, to the outer surface of the first or second wall 22, 24 of the cooling plate 20. In other embodiments, the protruding members 30 may be formed in the first or second wall 22, 24. The protruding members 30 are arranged at spaced-apart intervals along the length of the cooling plate 20 so as to correspond to the locations of the plurality of recessed openings 18 formed in the base portion 16 of the battery unit 11. As the battery unit 11 is positioned on and brought into contact with the cooling plate 20 (see
Furthermore, the mechanical interlock provided by the “peg and socket connection” of the protruding members 30 and recessed openings 18 provides for a generally low thermal resistance between the battery unit 11 and the cooling plate 20 when compared to other heat flow path thermal resistances. As well, the number of recessed openings 16 and corresponding protruding members 30, as well as their spatial distribution on the cooling plate 20, is selected so as to minimize thermal constriction (conduction) resistance in both the outer housing 14 of the battery unit 11 and the cooling plate 20.
Additionally, by individually connecting the battery units 11 to the cooling plate 20, the need for binding a plurality of battery units 11 (or cells) into modules is reduced. As well, the requirement for the individual battery units 11 and the cooling plate 20 to have flat or otherwise conformal contact surfaces, as is required in a number of known prior art arrangements, is no longer of great concern since the connection or contact between the battery unit 11 and the heat exchanger structure 12 is provided by the mechanical engagement between the first and second engaging devices i.e. the recessed openings 18 and the protruding members 30, and does not rely solely on the apparent contact between two, corresponding surfaces.
While the example embodiment has been described with the battery unit 11 having a base portion 14 formed with recessed openings 18 and the cooling plate 20 having the protruding members 30, it will be understood by persons skilled in the art that the reverse arrangement, i.e. having the base portion 16 of the battery unit 11 being formed with the protruding members 30 with recessed openings 18 being formed on one of the first and second walls 22, 24 of the cold plate 20, is also possible and may be desirable based on the particular application and/or design of the overall heat exchanger and battery unit structure. As well, while the heat exchanger structure 12 has been shown as a generally, rectangular tubular member with spaced-apart walls 22, 24, it will be understood that the heat exchanger structure 12 may instead be formed of a pair of mating plates which are brazed or suitably joined together to create fluid channel 26 therebetween. Additionally, as briefly described above, the fluid channel 26 may be in the form of a generally U-shaped flow path extending from the inlet structure 27 to the outlet structure 28 to ensure that the cooling fluid entering and exiting the heat exchanger structure 12 flows along the entire length of the cooling plate 20. The U-shaped flow path may be formed by corresponding inwardly depending ribs formed on the inner surfaces of each of the first and second walls 22, 24 or by means of a baffle member inserted within the fluid channel 26. Whether the fluid channel 26 is U-shaped or has any other form, the fluid channel 26 may also be equipped with additional heat transfer enhancing devices such as turbulizers positioned in the fluid channel 26 or inwardly disposed dimples formed on the inner surfaces of the first and second walls 22, 24, for instance, which increase turbulence in the fluid flowing through the channel 26 which serves to increase heat transfer effectiveness, as is known in the art.
Accordingly, the above-described example embodiment is not intended to be limited to the particular arrangement described or shown in the associated drawings. Furthermore, while the first and second engaging devices have been described as comprising, respectively, recessed openings 18 and protruding members 30, it will be understood that the first and second engaging devices may be in the form of any suitable corresponding, engaging structures provided on the cooperating surfaces of the battery unit 11 and the heat exchanger structure 12 which serve to create a mechanical interlock between the battery unit(s) 11 and the heat exchanger structure 12.
Furthermore, while the example embodiment has been described in connection with battery units 11 formed in the shape of generally rectangular cells, it will be understood by persons skilled in the art that the battery unit 11 may be in one of many different forms including, but not limited to, battery units in individual cylindrical or rectangular outer casings or housings, or any other prismatic form.
Referring now to
In the subject embodiment, the cooling plate 20 of the heat exchanger 12 is provided with one or more annular rings 36 that function as collared-openings which are attached to the outer surface of one of the first and second walls 22, 24 of the cooling plate 20 by any suitable means (i.e. welding, brazing, soldering, etc.). The annular rings 36, therefore, constitute the second engaging device and have an inner diameter 38 that is sized so as to receive the base portion 16 of the battery unit 11. Accordingly, the battery unit 11 is received within the corresponding collared-opening of the annular ring 36 provided on the cooling plate 20. In the case where a plurality of cylindrical battery units 10 are provided, each individual battery unit 10 can be mounted on and “locked” (either removably or irremovably) to the cooling plate 20. As in the previously described embodiment, the number of annular rings 36 provided on the cooling plate 20 and the manner in which they are distributed and spaced-apart on the cooling plate 20 is specifically selected to ensure that optimal cooling characteristics are achieved in accordance with known thermal resistance (conductivity) principles.
As shown more clearly in
As mentioned above, while the subject embodiment has been described in connection with a battery unit 11 having an outer housing 14 in the form of a cylindrical can with circular top and bottom surfaces 32, 34 with corresponding, generally circular, collared-openings or annular 36 being provided on the cooling plate 20, it will be understood that the outer housing 12 of the battery unit 11 may be in the form of a cylindrical can with square, rectangular, triangular or any other shape of top and bottom surfaces 32, 34. Similarly, the collared-openings 36 may be formed so as to correspond to the particular shape of the battery unit 11 and are not intended to be limited to the circular rings illustrated in the drawings.
Referring now to
Referring now to
The heat exchanger 12 is made up of spaced-apart first and second walls 22, 24 defining a fluid channel 26 therebetween, as described previously. A fluid inlet and a fluid outlet 27, 28 are also provided with the heat exchanger 12 that are in communication with the fluid channel 26, for directing fluid into and out of the fluid channel 26, as described previously. The first engaging device has a plurality of spaced-apart protruding members 52, which are coupled to a base plate 51 of the first engaging device. The plurality of spaced-apart protruding members 52 are adapted for releasably-affixing the battery unit 11. While the base plate 51 can contain recesses or peg, as described with reference to
In this embodiment, the base portion of each battery unit 11 corresponds to a bottom portion of the outer housing 14 and does not constitute a separately formed component that is subsequently attached to the bottom surface of the outer housing 14, as is described in the previous embodiment. Further, different types of batteries, such as having the outer housing made out of a hard cover or a flexible pouch can be used. As shown in
The method of attaching the plurality of protruding members 52 to the base plate 51 is not particularly limited. In one embodiment, the plurality of protruding members 52 are brazed, soldered, welded or mechanically attached to the base plate 51.
The shape and number of pins 58 on the protruding members 52 is not particularly limited, and can be set depending upon the particular application and requirements of the heat exchanger 12 and the heat exchanger and battery unit system 50. Similarly, the shape of brackets 62 is not particularly limited, as long as they are sufficiently complementary for receiving the pins 58 to couple the fins 54, 56 to the first wall 22. Also, the number of brackets 62 is not particularly limited, and can be more or less than the number of pins 58, so long as the fins 54, 56 can be coupled to the first wall 22. In the embodiment shown in
In the heat exchanger 12 and the heat exchanger and battery unit system 50, the battery unit 11 can be releasably-affixed to the protruding members 52. In the embodiment disclosed in
As shown in the embodiment disclosed in
In an alternate embodiment, the battery unit 11 can be affixed to the fins 54, 56, such that the battery unit 11 and the fins 54, 56 form a unit that can be coupled together to the first wall 22 of the heat exchanger 12. In such an embodiment, the battery unit 11 is affixed to the fins 54, 56 so that it cannot be separated from the fins 54, 56 without deforming or affecting the fins 54, 56 or the battery unit 11.
The shape and number of fins 54, 56 present in the heat exchanger 12 or the heat exchanger and battery unit system 50 are not particularly limited and can be established depending upon the requirements of the application. In the embodiment disclosed in
The number of battery units 11 in the heat exchanger and battery unit system 50 is not particularly limited and can be established considering the application and the requirements of the heat exchanger and battery unit system 50. In one embodiment, a single battery unit 11 is releasaby-affixed by a plurality of protruding members 52. In the embodiment disclosed in
The heat transfer from the battery unit 11 can take place through the protruding members 52, such as the fins 54, 56 that are in contact with the battery unit 11 and the first wall 22 of the heat exchanger 12. The pins 58 present on the fins 54, 56 can provide additional surface area for contact with the first wall 22 of the heat exchanger 12 and also can assist in improving the heat transfer efficiency. In addition, the battery unit 11 can itself have a face that is in contact with the first wall 22 of the heat exchanger 12, such as that shown in
The various embodiments presented above are merely examples and are in no way meant to limit the scope of this disclosure. Variations of the innovations described herein will be apparent to persons of ordinary skill in the art, such variations being within the intended scope of the present application. Accordingly, it will be understood that the subject matter described herein and in the recited claims intends to cover and embrace all suitable changes in technology.
Martin, Michael A., Burgers, John G.
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Executed on | Assignor | Assignee | Conveyance | Frame | Reel | Doc |
Oct 27 2011 | Dana Canada Corporation | (assignment on the face of the patent) | / | |||
Dec 20 2011 | MARTIN, MICHAEL A , MR | Dana Canada Corporation | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 027468 | /0096 | |
Dec 21 2011 | BURGERS, JOHN G , MR | Dana Canada Corporation | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 027468 | /0096 |
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